Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
  • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F10/02—Ethene
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
  • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/68—Vanadium, niobium, tantalum or compounds thereof

Definitions

• the invention relates to a catalyst system for the (co)polymerization of ethylene and optionally minor amounts of 1-alkenes and/or dienes, to the preparation of this catalyst system and to the (co)polymerization of ethylene and optionally minor amounts of 1-alkenes and/or dienes.
• polymerization takes place at temperatures that are only little above the temperature at which polyethylene dissolves, because the activity of catalysts customarily applied so far decreases at high polymerization temperatures. At unchanged residence time, this means that the polymer yield decreases, as a result of which the amounts of catalyst residues in the polymer increase and it soon becomes necessary to wash out the polymer.
• a problem in this exothermic polymerization reaction is the dissipation of the heat of polymerization. Cooling through the wall or by cooling devices in the reactor may easily lead to polymer deposition on the cooling surfaces, especially at cooling agent temperatures below 150):(C. For this reason, strong cooling of the reactor feed was preferred. This, however, costs much energy and will become more expensive as fuel prices rise.
• EP-A 57050 and EP-A 131 420 describe catalyst systems that are active at very high polymerization temperatures.
• the first component is the same as in EP-A 57050, while the second is an alkyl si- loxalane.
• the various components of these catalyst systems are mixed such that in the first component the atomic ratio of aluminium to titanium plus vanadium is between 0.2 and 2.0, and preferably more titanium than vanadium is present The optimum titanium : vanadium ratio is 85:15.
• the atomic ratio of the aluminium from the second component to titanium plus vanadium is at most 3.
• a disadvantage of these catalysts is that heating of the first component or a portion thereof prior to combination with the second component requires extra energy and is laborious. For industrial-scale polymerization, streamlining of the process is of prime importance. Intermediate heating of a portion of the catalyst system would interfere with this objective. In addition, a precipitate is formed on such heating, which may result in problems with the catalyst feed to the reactor.
• the invention aims to find a catalyst system not having the above-mentioned disadvantages without sacrificing activity or the capability of forming large polymer molecules at very high polymerization temperatures.
• a catalyst system that is a combination of at least two components, A and B, which components comprise:
• An advantage of a catalyst system according to the invention is that very high temperatures can be used to produce polyethylene that meets the customary requirements as regards processability and applicability and that contains such a small amount of catalyst residues that washing out of the product is not necessary.
• the catalysts according to the present invention not only are very active, but also very rapid, so that very short residence times will suffice.
• a short residence time has the great advantage that a small reactor may be used.
• an annual production of more than 50,000 ton can be reached when using the catalysts according to the invention.
• components A and B are fed direct to the reaction vessel, that is, without heating above 150 C and without recovery of a precipitate. Such additional operations even have an adverse effect on the catalyst system according to the invention.
• the residence time of the various catalyst components in the feed lines on the whole is sufficient for obtaining an active catalyst system. In most cases this residence time will not be more than some, for instance 5, minutes; often it will even be less, for instance less than 3 or even less than 1 minute. However, a longer residence time, though economically unattractive, in itself is not disadvantageous for the catalyst according to the invention. If for certain reasons it should be desirable to allow the combined catalyst components to stand for some time, for instance in the case of batch-wise polymerization, this does not entail a reduction of activity.
• Catalysts that are built up of two components are described in for instance, DE-A 2600366 and DE-A 1934677.
• the component containing transition metals is prepared via complicated intermediate steps, after wich the precipitate formed is recovered and thoroughly washed.
• These catalysts are intended for suspension polymerization and they are hardly active at polymerization temperatures in excess of 180 C.
• the polymers produced using these catalysts in addition, have such a high transition metal content as to necessitate washing out of the product.
• the catalyst systems according to the invention not only take less time to prepare, they also have a higher activity, with all associated advantages.
• Catalyst systems according to the invention are most active at an atomic ratio of aluminium from component A to the sum of titanium and vanadium of at least 5. It is to be recommended for the atomic ratio of chlorine to the sum of titanium and vanadium to be at least 7.5, in particular at least 9. A further increase in activity is achieved at an atomic ratio of aluminium from component B to the sum of titanium and vanadium of at least 3. Further, an atomic ratio of titanium to vanadium of at most 1, and in particular of at most 0.8, is to be preferred. Usually, the atomic ratios of aluminium to the sum of titanium and vanadium, of chlorine to the sum of titanium and vanadium and of aluminium from component B to the sum of titanium and vanadium will not exceed 100:1, in particular 50:1. The atomic ratio of titanium to vanadium will usually be at least 0,001:1, in particular 0,01:1.
• vanadium compounds use can be made of compounds of the general formula VO(OR3)3-pX3p, where R 3 represents a hydrocarbon residue with 1-20 carbon atoms, X 3 a halogen atom, and 0 s p s 3, in particular vanadyl chloride and/or vanadyl butoxide. It is also possible to use vanadium compounds of the general formula VX4 3 or VX4 4 , where X4 represents a halogen atom. X 4 preferably is a chlorine atom. Mixtures of titanium compounds or vanadium compounds can also be used as catalyst ingredients.
• organoaluminium compounds of component A are DADHMS, DADS, DEAC, MEAC, MMAC, SEAC, SMAC, TEA, TIBA, TMA.
• DEAC and/or SEAC yield good results. (See list of abbreviations on page 11).
• the organoaluminium compound of component B may be the same as that of component A, but this need not be so.
• a good result is obtained when applying compounds with the general formula R 5 S AlY 3-s , where the symbols R 5 are equal or different and represent a hydrocarbon residue with 1-20 carbon atoms, Y represents a hydrogen atom, a hydrocarbon residue with 1-20 carbon atoms, a group having the general formula -NR 6 (where R6 is a hydrocarbon residue with 1-20 carbon atoms), or a group having the general formula -OR 7 (where R 7 is a hydrocarbon residue with 1-20 carbon atoms or a group having the general formula -Si(R8) 3 , where the symbols R8 are equal or different and represent a hydrogen atom and/or a hydrocarbon residue with 1-20 carbon atoms), and 0 ⁇ s a 3.
• an alkyl aluminoxane (a compound of the general formula R 2 AI-[OAI(R)]b-OAIR 2 , where the symbols R are equal or different and represent a hydrocarbon residue with 1-10 carbon atoms, and b ⁇ 0) can also be applied as component B with good results. Mixtures may also yield good results.
• a further increase in activity is achieved if, besides the organoaiuminium compound(s), one or more other metal alkyls are added to component B such as, for instance, dialkyl magnesium-, dialkyl zinc-, tri- alkylboron-, alkyl lithium compounds.
• organoaluminium compounds of component B are: methylaluminoxane, DADHMS, DADS, DATPS, DEAC, DEAH, DEALOX, IPRA, MEAC, SEAC, TEA, TIBA, TIBAO, DIBBA, DIBAH, TOA. (See the list of abbreviations on page 11).
• a chloride may also be added to component B.
• Catalyst systems according to the reactor may be fed to the reactor separately or in combination. However, a better result is obtained when components A and B are separately fed to the reactor. When components A and B are fed separately to the reactor, it is immaterial in what order this is done. The sequence in which the ingredients of the components themselves are mixed is not very important, either.
• component A for instance, first a titanium and a vanadium compound can be mixed, then an organoaluminium compound can be added and finally, optionally, a chloride and/or an electron donor.
• the organoaluminium compound may also first be mixed with a chloride and subsequently with a titanium and a vanadium compound. It is also possible to add the organoaluminium compound to one of the transition metal compounds before the second transition metal compound is added. It may be preferable to mix the vanadium and titanium compounds in advance, especially when one of them is less stable, such as VOCI 3 .
• the transition metal compounds with the organoaluminium compound at a temperature below 125 C, in particular below 75 C, more in particular below 50HC. In general the temperature will not be below -60 C.
• component B here too the sequence of mixing, if any, can freely be determined, without the giving rise to a significant deterioration of catalyst activity.
• This third component may be a chloride and/or electron donor, in particular a chloride or aryl or alkyl or an element of groups 3a and 4a of the Periodic System, or an organoaluminium chloride.
• the invention also relates to polymers obtained by means of a catalyst according to the invention.
• These polymers comprise ethylene, one or more 1-alkenes with 3 to 18 carbon atoms in an amount of 0 to 15 mole.% relative to the total polymer, and one or more dienes with at least 7 carbon atoms in an amount of 0 to 10 mole.% relative to the total polymer.
• dienes contain at least two non-conjugated double bonds capable of being polymerized by means of transition metal catalysts, and in which the amount of dienes does not exceed 0.1 mole.% relative to the total polymer, have good properties.
• Polymers according to the invention may contain the customary additives, such as stabilizers, lubricants, and also, for instance, crosslinking agents and fillers.
• Polymers obtained by means of a catalyst according to the invention possess the customary properties that are commercially desired, such as a sufficiently high molecular weight (low melt index) and good processability. They can be used for the preparation of cast film and blown film having good mechanical and optical properties, while also the rheological and welding properties meet the normal requirements.
• the polymers are also suitable for many other customary applications, e.g. injection moulding and rotational moulding.
• Polymerization can be effected in a manner known in itself, both batchwise and continuous.
• the catalyst components, prepared in advance are added in such amounts that the amount of titanium in the polymerization medium is 0.001 to 4 mmol/l, preferably 0.005 to 0.5 mmolil, and more in particular 0.01 to 0.05 mmoul.
• dispersing agent both in the catalyst preparation and in the polymerization, use can be made of any liquid that is inert relative to the catalyst system, for instance one or more saturated, straight or branched aliphatic hydrocarbons, such as butanes, pentanes, hexanes, heptanes, pentamethylheptane or petroleum fractions such as light or regular-grade petrol, isopar, naphtha, kerosine, gas oil.
• Aromatic hydrocarbons for instance benzene or toluene, can be used, but both because of the cost price and for safety considerations such solvents will generally not be applied in technical-scale production.
• the polymerization is effected at temperatures above 180 C, especially above 200 C, and more in particular at temperatures above 220 C.
• the temperature will generally not be higher than 300MC.
• the polymer solution obtained upon polymerization can subsequently be recovered in a way known in itself, the catalyst generally being deactivated at some stage of the recovery. Deactivation can be effected in a way known in itself.
• the catalysts according to the present invention are so active that the amount of catalyst in the polymer, notably the transition metal content, is so low that removal of catalyst residues can be done without.
• the polymer can be subjected to a washing treatment so as to further reduce the residual content of catalyst components, if this is deemed necessary.
• Polymerization can be effected under atmospheric pressure, but also at elevated pressure, up to about 1000 bar, or even higher, both in continuous and in discontinuous manner. By effecting the polymerization under pressure, the polymer yield can be increased further, which may contribute to the preparation of a polymer having very low contents of catalyst residues. It is preferred to polymerize at pressures of 1-200 bar, and more in particular of 10-100 bar.
• the molecular weight can be controlled by addition of hydrogen or other customary modifying agents.
• Polymerization can also be effected in various stages, connected either in parallel or in series, in which, if desired, differing catalyst compositions, temperatures, residence times, pressures, hydrogen concentrations, etc. are applied.
• Products with a broad molecular weight distribution can be prepared by selecting the conditions in one stage, for instance pressure, temperature and hydrogen concentration, such that a polymer with a high molecular weight is formed, while the conditions in another stage are selected such that a polymer with a lower molecular weight is formed.
• the catalyst components were mixed as indicated in Table 2.
• the catalyst preparation and the polymerization were effected in the same way as in Example I, now however at a reactor pressure of 8 bar.
• the catalyst was composed as shown in Table 3, and polymerization was effected as in Example II.
• Component A was prepared by stirring 9 mmol TiCI 4 and 9 mmol VB during 2 hours in 10 ml PMH in a glass vessel under nitrogen, the temperature being 60 C. Subsequently 27 mmol SEAC was added dropwise at 20 C, and the mixture was stirred during three hours at 20 C. After decantation, the precipitate was washed 6 times with 40 ml PMH.
• Component A was prepared by treating 9 mmol TBT, 9 mmol VOCl 3 and 27 mmol SEAC as in Comparative example 2. With 0.4 mmol DEALOX as component B and polymerization conditions as in Example II, the catalyst was not active.
• Component A was prepared by treating 4.5 mmol TiCI 4 , 4.5 mmol VB and 54 mmol SEAC as in Comparative example 2.
• Component A was prepared by treating (2 mmol TBT + 3 mmol VB + 10 mmol BzCI) and 30 mmol SEAC as in Comparative example 2. With 0.4 mmol/l TEA as component B and polymerization conditions as in Example II, an acitivity of 341 was achieved.
• Component A was prepared by dropwise addition to 12 mmol SEAC at 25 C of a solution of 5 mmol TBT + 5 mmol VOCl 3 , which had been aged for 4 days. The resultant suspension was filtered off and the solid matter washed and dried. After this, 2.73 g of the solid was added to 1.58 g TiCl 4 in 10 ml hexane. The precipitate formed after 3 hours' reacting at 25 C was recovered, washed, dried and resuspended.
• Example II Polymerization further was effected as in Example II, with such an amount of the suspension that the total concentration of transition metals was about 0.1 mmol/l.
• component B use was made of 0.4 mmol/l TEA or 0.4 mmol/l DEALOX. In neither case was the catalyst active.
• Component A was prepared by reacting a titanium and a vanadium compound, as indicated in Table 5, in PMH at room temperature with DEAC. After mixing for 40 seconds at room temperature, the mixture was heated to 185 C for 1.5 minutes and fed to the reactor. Subsequently TEA or DADS was fed to the reactor as component B, as indicated in table 5. Polymerization further was effected as in Example II.
• Component A was prepared by mixing the ingredients listed in Table 6 at the temperatures shown in the same table. To this end, the PMH in which the ingredients were mixed was in advance brought at the indicated temperature. Otherwise the process of Example 1 was adhered to. As component B, 0.4 mmol/l DADS was used.
• Example II ethylene-octene copolymerizations were effected as in Example I. Prior to the ethylene, 1-octene was fed to the reactor in the amounts (in ml) given in Table 7. The density of the polymer in kg/m 3 was determined in accordance with ASTM D 1505.

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• Chemical & Material Sciences (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Transition And Organic Metals Composition Catalysts For Addition Polymerization (AREA)
• Polyethers (AREA)
• Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)

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• 1986
  • 1986-01-11 NL NL8600045A patent/NL8600045A/nl not_active Application Discontinuation
  • 1986-04-11 US US06/850,688 patent/US4704376A/en not_active Expired - Fee Related
  • 1986-12-10 US US06/940,080 patent/US4739022A/en not_active Expired - Fee Related
  • 1986-12-12 IN IN969/MAS/86A patent/IN169292B/en unknown
  • 1986-12-16 ES ES86202273T patent/ES2015531B3/es not_active Expired - Lifetime
  • 1986-12-16 AT AT86202273T patent/ATE52096T1/de active
  • 1986-12-16 DE DE8686202273T patent/DE3670497D1/de not_active Expired - Lifetime
  • 1986-12-16 EP EP86202273A patent/EP0229422B1/en not_active Expired - Lifetime
  • 1986-12-29 KR KR1019860011658A patent/KR900000568B1/ko not_active IP Right Cessation
• 1987
  • 1987-01-09 SU SU874028813A patent/SU1641193A3/ru active
  • 1987-01-09 JP JP62001991A patent/JPS62167304A/ja active Pending
  • 1987-01-09 AU AU67439/87A patent/AU597613B2/en not_active Ceased
  • 1987-01-09 ZA ZA87160A patent/ZA87160B/xx unknown
  • 1987-01-10 CN CN87100132A patent/CN87100132B/zh not_active Expired
  • 1987-01-12 BR BR8700096A patent/BR8700096A/pt unknown

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